LHB COACH

SALIENT
FEATURES
NEW GENERATION COACHES

LHB
DESIGN
COACHES
 NEED FOR NEW TECHNOLOGY- I

INDIAN RAILWAY HAS BEEN

MANUFACTURING PASSENGER COACHES OF
“SCHLIRIEN” DESIGN FOR MORE THAN LAST 50
YEARS.
ALTHOUGH CONTINUOUS EFFORTS WERE
BEING PUT TO UPGRADE THESE COACHES, BUT A
NEED WAS ALWAYS FELT TO IMBIBE
TECHNOLOGY IN-USE DEVELOPED COUNTRIES SO
AS TO AFFECT A QUANTUM JUMP IN QUALITY OF
COACHES.
 NEED FOR
NEW TECHNOLOGY - II
THIS WAS THE BASIC REASON BEHIND SETTING UP OF “RAIL
COACH FACTORY” AT KAPURTHALA.

EXTENSIVE STUDIES WERE DONE TO LOCATE THE RIGHT

TECHNOLOGY FOR INDIAN CONDITIONS.

TWO CONTRACTS FOR TRANSFER OF TECHNOLOGY AND SUPPLY

OF FIRST TWO RAKES (24 COACHES) WERE SIGNED WITH M/S
LINKE HOFFMAN BUSH(LHB) (NOW ALSTOM LHB), GERMANY IN
1995.
 ALSTOM -LHB, GERMANY
“M/S ALSTOM LHB” ARE ONE OF THE LEADING
MANUFACTURER IN TRANSPORT SECTOR HAVING PRESENCE IN
MOST OF THE EUROPEAN COUNTRIES.

COACHES MANUFACTURED BY THEM ARE RUNNING IN

MANY COUNTRIES ACROSS THE GLOBE.

FOR THIS CONTRACT THE BOGIES WERE DESIGNED AND

MADE BY M/S FABRICA ITALIANA d e AUTIMOBELE TORINO
(FIAT), SWITZERLAND WHICH IS NOW A PART OF ALSTOM
GROUP.
 SUPPLY CONTRACT
COVERED SUPPLY OF
❑ 19 SECOND CLASS AC CHAIR CAR
COACHES.
❑ 2 EXECUTIVE CLASS CHAIR CAR
COACHES.
❑ 3 GENERATOR CUM BRAKE VANS
 CONTRACT FOR
TRANSFER OF TECHNOLOGY -I
COVERED THE FOLLOWING :
– TRANSFER OF TECHNOLOGY FOR ALL
COACHES SUPPLIED BY THEM i.e. CHAIR CAR
AND POWER CAR
– DEVELOPMENT OF LAYOUTS AND KEY
DESIGNS FOR CARBODY SHELLS FOR
– AC FIRST CLASS
– AC TWO TIER SLEEPER
– AC HOT BUFFET CAR
 CONTRACT FOR
TRANSFER OF TECHNOLOGY -II
IT ALSO COVERED
– ASSISTING RCF IN
• DEVELOPING AND MANUFACTURING ALL ABOVE
COACHES
• DEVELOPING “SG” VERSION OF FIAT BOGIE
• ESTABLISHING INDIGENOUS SOURCES OF
BOUGHT-OUT ITEMS.
– PROVIDING TRAINING TO “IR” PERSONNEL IN
MANUFACTURE AND MAINTENANCE OF THESE
COACHES.
LHB COACH EXTERIOR VIEW (IMPORTED)
HOW IT BENEFITS
RAILWAYS
 A LONGER COACH
LHB COACHES ARE APPROXIMATELY 2-METERS
LONGER THAN THE CONVENTIONAL ICF TYPE
COACHES.
THIS MEANS “MORE TRAVEL SPACE”
“INCREASED SEATING CAPACITY”,
“WIDER BAYS AND DOORWAYS” ETC.
 A LONGER COACH
LHB COACHES ARE APPROXIMATELY
2 - METERS LONGER THAN THE
CONVENTIONAL ICF TYPE COACHES.
THIS MEANS “MORE TRAVEL
SPACE” “INCREASED SEATING
CAPACITY”, “WIDER BAYS AND
DOORWAYS” ETC.
 A LIGHTER COACH
PER METER LENGTH, WEIGHT OF LHB
COACH IS APPROXIMATELY “10%” LESSER
THAN THE CONVENTIONAL COACH.
THIS NOT ONLY MEANS
LOWER HAULAGE COSTS BUT
ALSO LESS WEAR AND TEAR
OF THE COACHES AND TRACK.
 A HIGHER SPEED COACH
LHB COACHES ARE DESIGNED TO
RUN AT A MAXIMUM SPEED OF
180 KMPH.
EVEN FOR SPEEDS OF 200
KMPH, NO MAJOR
CHANGES ARE REQUIRED
 LESSER MAINTENANCE
$ USE OF SUPERIOR MATERIALS WITH LONGER LIFE.
$ SUPERIOR BRAKING WITH WHEEL SLIDE PROTECTION.
$ BOGIE WITH LESS MOVING PARTS.
$ ITEMS OF WEAR & TEAR SHALL NOT REQUIRE
REPLACEMENT/RENEWAL BEFORE 10LAKH KMs.
$ USE OF STAINLESS STEEL AND LESS BOGIE MOVING PARTS SHALL
REDUCE MAINTENANCE REQUIREMENTS.
$ ENTRANCE DOORS FLUSH WITH SIDE WALL ALLOWING AUTOMATIC
CAR WASHING.
$ CORROSION ALMOST FREE DUE TO EXTENSIVE USE OF STAINLESS STEEL
AND SURFACE PROTECTION MEASURES.
$ SHORTLY INTRODUCED BOI-TOILET, WHICH IS ABSOLUTELY MAINTE-
NANCE FREE SYSTEM.
Stainless Steel Shell
 MANUFACTURING TECHNIQUES
• Gluing of window frame
to shell body

• Robotic garnet blasting of

shell
 Manufacturing Techniques

Flooring Support
Members on
Under-frame

Provision for CBC

as well a side
buffer mounting in
head stock
 MANUFACTURING TECHNIQUES
• Laser Profile Cutting Of
Components.
• Magnetic Skin Tensioning Of
Shell.
• Side-Wall / Roof Spot
Welding.
 FRP ITEMS
• NO. OF FIRE RETARDENT FRP ITEMS HAVE BEEN
USED IN THE INTERIORS FOR
– IMPROVED AESTHETICS
– ABILITY OF FRP TO BE MOULDED INTO
INTRICATE SHAPES/CURVED SURFACES,
AVOIDS JOINTS
– BETTER STRENGTH TO WT RATIO
– SCRATCH RESISTANCE
– RESILIENCE TO SMALL DENTS
– EASY REPAIREABILITY
 FRP LAVATORY MODULE
(PVC FOAM SANDWICHED BETWEEN FRP)

FRP, AC UNIT TROUGH

FRP SIDE WALL PANEL

FIRE RETARDANT MATERIAL USED IN COACHES
Description RDSO Spec No.
Wood based impregnated compressed laminates (compreg) C-9407 (Rev.3)
Fire retardant upholstery cloth C-9901
Fire retardant curtain fabric C-9911
NFTC roof ceiling C-K511
Decorative thermosetting synthetic resin bonded laminated C-K514
sheets (LP sheets) for interior furnishing of coaches.
Densified thermal bonded polyester blocks for use in C-K607
railway coaches for seats and berths
Flexible vinyl flooring (PVC) for use in coaching stock. RDSO/2006/CG-
12
Fibre glass reinforced plastic (FRP) windows of BG RDSO/2007/CG-
mainline coaches. 02
UIC type elastomer flange connection between passenger RDSO/2007/CG-
coaches of Indian Railways. 05
WINDOWS
TIGHT-LOCK CENTRE BUFFER COUPLER
• AAR H-type coupler
– Vertical interlocking provides anti climbing feature
• Adequate strength for hauling :
– 26 coaches at 110 kmph
– 18 coaches at 160 kmph
 HOW IT
BENEFITS THE
PASSENGER
 BETTER RIDE QUALITY
 IMPROVED RIDE COMFORT - RIDE INDEX REDUCED FROM OVER 3.
0 TO 2. 5 AT A SPEED OF 160 KMPH.
 PLUSH INTERIORS OF INTERNATIONAL STANDARDS.
 IMPROVED AIR-CONDITIONING THROUGH BETTER DUCT
DESIGNING & HUMIDITY CONTROL.
 BIGGER SIZE SEALED WINDOWS FILLED WITH “ARGON” GAS FOR A
PANORAMIC VIEW & HEAT INSULATION.
 MODULAR “ORIENTAL” & “WESTERN” STYLE TOILETS WITH “CDTS”
TO AVOID SOILING OF STATION PREMISES. GREEN TOILET SHORTY
INTRODUCED SHORTLY.
 WELL EQUIPPED PANTRY WITH HOT CASES, DEEP FREEZER, BOTTLE
COOLERS ETC.
 FLUSH TYPE SWIVELING BERTH READING LIGHT.
 POLYCARBONATE TRANSPARENT CENTRE TABLES.
 MORE SAFE
• SAFETY OF PASSENGERS IS OF PARAMOUNT IMPORTANCE,
SO A NUMBER OF PRECAUTIONARY MEASURES HAVE BEEN
ADOPTED IN LHB DESIGN COACHES , LIKE :-
❑ FOUR EMERGENCY EXIT WINDOWS FOR FASTER PASSENGER
EVACUATION DURING EMERGEN-CIES.
❑ WIDER VESTIBULE DESIGN FOR SMOOTH INTER COACH
MAVEMENT.
❑ CONVENIENT TO OPERATE EMERGENCY ALARM PULL
OPERATION AND FIRE RETARDANT FURNISHING.
❑ TIGHT LOCK CENTRE BUFFER COUPLER MAKES COACHES
ANTI-CLIMBING.
❑ SUPERIOR BRAKING SYSTEM.
❑ FIRE RETARDANT MATERIALS.
❑ PROPER COACH EARTHING.
❑ PUBLIC ADDRESS SYSTEM.
❑ SMOKE & FIRE ALARM SYSTEM
❑ EMERGENCY ACCIDENT LIGHT
 EARLY FIRE AND SMOKE DETECTION SYSTEM
• Plan to provide Early Fire
and Smoke Detection
System on 20 rakes
• Coach unit will detect
presence of smoke at very
early stage by sampling air
• Will activate audio visual
alarm
• Heat activated sensors for
toilets
• Central Monitoring of all
the coaches

29-Jul-20 28
FIRE & SMOKE DETECTION & EARLY WARNING
SYSTEM

29
Vestibule door

Pantry door

Fire Extinguisher

Antiskid PVC
flooring
FIRE EXTINGUISHER
PROVIDED IN THE
ENTRANCE AREA
 SUPERIOR
AESTHETICS
LHB COACH INTERIOR
SWITCH BOARD CABINET
LUGGAGE RACK
European
Style

Toilet

Indian
Style
Toilet
COAT HOOK PROVIDED IN LAVATORY
 PASSENGER

COMFORTS
BACK SIDE OF SEAT ATTENDANT SEAT
Reading lights provided in Lugagge Rack
 Screw less Modular interiors

Sliding Coat
hooks
provided in
Luggage
Rack
 PASSENGER
CONVENIENCE
SPACIOUS
ENTRANCE
AREA
 AIR DIFFUSER
PROVIDED IN
CEILING OF
LAVATORY

LAVATORY ENGAGED
INDICATOR IN
PASSENGER AREA
WIDER
PASSENGER
COMPARTMENT
DOOR
WITH BIGGER
GLASS UNIT
Flush Button/
Switch

Toilet Paper
Holder

Hand Grip

Water for
toilet use

Ashtray or
Lotah

Drain
 110V/220V
Socket for
shaver

Push button for

water supply

Water outlet
for hand wash

Soap
Dispenser
AIR
DIFFUSER

MIRROR

FLUORESCENT
LIGHT

ASH TRAY

WASH BASIN
DETAILED DESIGN
FEATURES OF

LHB
COACH
 LHB COACH DESIGN
MAJOR FEATURES
 LENGTH OVER BODY = 23540 mm (21337mm)
 MAX. DISTANCE BETWEEN INNER
WHEELS = 12345 mm (11887mm)
 MAX. BUFFER DROP = 75 mm
 MAX. TARE WEIGHT = 40.287 t

 NO OF PASSENGERS = 78 (2ND AC C.CAR)

= 56 (EXEC. AC C.CAR)
 TEST SPEED POTENTIAL = 180 KMPH
 RIDE INDEX OF COACH = 2.5 BUT NOT EXCEEDING 2.75
 FLOATING FLOOR = DUE TO D-COUPLING ELEMENT
 REDUCED SPACE BETWEEN COACHES = LOWER WIND RESISTENCE
 MAINTENANCE CRITERION = ITEMS OF WEAR & TEAR SHAL
NOT REQUIRE REPLACEMENT
RENEWAL BEFORE 1 MILLION KMs.
USE OF STAINLESS STEEL AND LESS BOGIE MOVING PARTS SHALL REDUCE
MAINTENANCE REQUIREMENTS
 AT A GLANCE COMPARISON OF WEIGHT AND CAPACITY
Weight Capacity Weight Capacity
(T) (T)

LHB/EOG ICF/EOG

FAC 43.3 24 FAC 46.2 18

ACCW 44.6 52 ACCW 44.8 48
ACCN 45.6 72 ACCN 48.3 64
CB 40.9 0 CB 47.9 0
WLRRM 53 0 WLRRM 60 0

LHB WEIGHS LESS BY 50.6 TONNES CAPACITY MORE BY 78 PASSENGERS

 COACH SHELL
STAINLESS STEEL MATERIAL
SIDEWALL & ROOF STRUCTURAL MEMBERS IN FERRITIC
STEEL
SIDEWALL AND ENDWALL SHEETS OF FERRITIC STEEL
ROOF SHEET & TROUGH FLOOR IN AUSTENITIC STEEL
IRSM-41 STEEL FOR ALL OTHER STRUCTURAL
MEMBERS. 6 MM SOLE BAR.
STRUCTURAL JOINTS
INTER-LOCKING JOINTS OF VERTICAL & HORIZONTAL
MEMBERS
 INTERLOCKING BETWEEN THE INTERLOCKING OF JOINTS
HORIZONTAL AND VERTICAL
STIFFENING MEMBERS OF SUB
ASSEMBLIES LIKE SIDE WALL,
END WALL,UNDER FRAME, ETC.
 ALIGNED STRESS FLOW
 BETTER STRENGTH
 REDUCTION OF SIDE WALL
WIDTH FROM 90 MM TO 60MM

 BETTER GEOMETRICAL INTEGRITY

RCF KAPURTHALA
RESISTANCE TO DISTORTION
55
 USE OF COMPOSITE MATERIALS
“ALUCOBOND” LAVATORY
CEILING PANEL & ALUMINIUM
HONEY COMB PARTITION PANELS

IMPROVED AESTHETICS
VERY GOOD SURFACE FINISH
CORROSION RESISTANCE
 BETTER RIGIDITY
HIGHER STRENGTH TO WEIGHT
RATIO
CAN UNDERGO PROCESSES SUCH
AS ROLLING, BENDING, CUTTING,
WELDING ETC. WITHOUT LOOSING
OUT ON IT’S PROPERTIES

FLOOR BOARDS 4 MM CORK

SANDWICHED BETWEEN
COMPREG TO ABSORB NOISE
Manufacture of Honeycomb Panel
SHELL STRUCTURE

RCF KAPURTHALA 58
RUBBER DE-COUPLING ELEMENTS IN FLOORING RESULT IN SUPERIOR
NOISE AND VIBRATION ABSORPTION
Floor Board
4 mm cork
Rubber element
Metallic floor support
member
FLOATING FLOOR
 SIDEWALL TO UNDER FRAME JOINT
CONVENTIONAL VS. LHB

 TURN UNDER HAS BEEN ELIMINATED

 CLEAR APPROACH FOR SAND BLASTING AND PAINTING
 NO ACCUMULATION OF WATER AND MUCK
 PILLAR RESTS ON SOLEBAR AS COMPARED TO LOAD TRANSFER
THROUGH A VERTICAL WELDED JOINT IN CONV. COACHES
 SHELL CORROSION PROTECTION
WELDABLE ALUMINIUM PAINT TO AVOID
BI-METALLIC CORROSION
SAND BLASTING AND IMMEDIATE
PAINTING
NOISE & CORROSION PROTECTION COAT
“BARYSKIN V60DB” SPRAYED ON SHELL
INTERIOR
“RESONAFLEX ALU” OR RUBBER FOAM
INSULATION AVOIDS WATER COLLECTION
 USE OF “RESONAFLEX”
(DIAGONALLY GLUED PLATED
CELLULOSE ACETATE FILM, LIGHT
WEIGHT, HIGH THERMAL
RESISTANCE) ON SIDE WALL &
FLOOR AND GLASS WOOL ON ROOF
AND SIDE WALL (ABOVE WINDOW)
PROVIDE HEAT INSULATION.
RESONAFLEX ON UNDER FRAME
PREVENTS WATERABSORPTION /
RETENTION

GLASS WOOL PADS HELD BY PINS, WELDED ON

THE ROOF
RESONAFLEX THERMAL INSULATION

Now
rubber
foam is
being used
 SUPERIOR INSULATION
“BARYSKIN V60DB” OR
EQ. SOUND INSULATION
PU PAINTS ON FULL
COACH SHELL INTERIOR,
PROVIDE ANTI DRUMMING
SOUND INSULATION AS
WELL AS CORROSION
RESISTANCE.

SOUND INSULATION OF 31 DB .

COATING OF 2-3 MM THICKNESS

IN THE COACH INTERIOR, 6-8 MM
IN BODY BOLSTER AREA.

EXTREMELY GOOD FIRE

RETARDANCY OF CLASS SR-4 TO
DIN 5510
DESIGN FEATURES
BOGIE
 ADAPTATION OF EUROFIMA DESIGN FOR IMPROVED RIDE COMFORT.
 DESIGNED FOR OPERATING SPEED OF-160 KMPH , TESTED AT 180 KMPH
AND HAS A POTENTIAL FOR OPERATION UPTO - 200KMPH.
 STRUCTURALLY SUPERIOR “Y- FRAME” BOGIE CONSTRUCTION MAKING IT
LIGHTER AND YET STRONER.
 IMPROVED PRIMARY AND SECONDARY SUSPENSION FOR SMOOTH AND
COMFORTABLE RIDING, OBTAINED BY USE OF FLEXICOIL SPRING.
 DIFFICULT TO MAINTAIN DASH-POT HAS BEEN ELEMINATED.
 EXTENSIVE USE OF ELASTOMERIC RUBBER-METAL COMPONENTS
 EQUIPPED WITH HYDRAULIC SHOCK ABSORBERS CONFORMING TO UIC
STANDARD WITH HIGHER LIFE CYCLE RATING.
 AXLE GUIDANCE IS PROVIDED BY AN ARTICULATED CONTROL ARM
THROUGH A RESILIENT BUSH WHICH WILL GIVE BETTER NEGOTIATION ON
CURVES.
 WHEEL, AXLE AND BRAKES
FORGED WHEELS TO IRS R-19 OF 915 MM DIA. MAX
USABLE WORN DIA 845 MM.
FORGED AXLES.
CARTRIDGE TAPER ROLLER BEARING FOR AXLES OF
“TIMKEN MAKE”.
GRADUATED TWIN PIPE RELEASE AXLE MOUNTED DISC
BRAKE WITH “ELECTRO-PNEUMATIC” FEATURE.
PASSENGER ALARM SYSTEM AVAILABLE WITH 19 MM
CHOKE.
 COACH INTERIORS
ERGONOMICALLY DESIGNED SEATS AS PER INDIAN
ANTHROPOMETRIC DATA.
LARGE WINDOWS WITH GOOD VISIBILITY.
ALUMINIUM LUGGAGE RACKS WITH INBUILT READING
LAMPS.
INSULATION AGAINST NOISE.
USE OF FIRE- RETARDANT FRP FOR PANELLING.
HAND-SAFE FEATURE IN ALL AUTOMATIC SLIDING DOORS.
ANTI-SKID PVC FLOORING.
UIC VESTIBULES AND AUTO CLOSING VESTIBULE DOOR.
 COACH INTERIORS
☺SEATS HAVE POWDER COATED ALUMINUM FRAME. SEAT
CUSHION & BACK-REST OF MOULDED “PU FOAM”. GAS
SPRING USED FOR RECLINING MECHANISM.
☺16 MM SANDWICH OF “MACORE WOOD & CORK” HAS
BEEN USED AS FLOOR PANEL. THIS IS LIGHT WEIGHT,
WATER & IMPACT RESISTANT.
☺CONTROLLED DISCHARGE TOILET SYSTEM (CDTS) HAS A
MICRO - PROCESSOR CONTROLLED INTERMEDIATE
WASTE TANK WHICH DISCHARGES WASTE ONLY AT
SPEEDS ABOVE 45 KMPH.
☺ INTRODUCED SHORTLY BIO - TOILET SYSTEM IN THE
RAILWAY COACHES.
 Doors
LHB coach has :
# 4 body side doors
# 2 compartment doors
# 3 lavatory doors
# 2 vestibule doors
# 1 pantry door
# 2 Roller shutters for pantry storage area
 Doors
➢Hinged type swing sandwich
doors
➢Stainless steel body filled with
Phenolic resin for better heat
insulation
➢Provided with sealed window glass
unit.
COMPARTMENT
DOOR
SLIDING MECHANISM OF DOOR
VESTIBULE
DOOR

PANTRY
DOOR
Storage area
for Serving
Trolley

Storage
area for
Pantry
 LAVATORIES
• LHB COACHES HAVE BOTH
ORIENTAL AND EUROPEAN
TYPE OF LAVATORIES WITH
CONTROLLED DISCHARGE
TOILET SYSTEM (CDTS).
 Waste Retention Tank

CDTS WASTE RETENTION TANK

Side view
of Luggage
Rack

Reading
lights
provided in
Luggage
Rack
 Passenger Emergency Alarm

• 5 passenger emergency alarms

per coach have been provided
at following locations:
–2 in passenger compartment
–3 in lavatories ( In earlier supplied coaches only)
Passenger Emergency Alarm
 Window Units
Three types of windows have been
used in LHB coaches:
•Fixed window - 12 Nos.
•Emergency open-able window- 4 Nos.
•Hopper type window for lavatory - 3
per coach
 Emergency open able window
• It is similar to the fixed unit
• Four units are provided each coach to
allow emergency evacuation of
passengers
• A handle connected to the rubber
profile opens the glass unit of the
emergency window
EMERGENCY WINDOW
 Handle

EMERGENCY OPEN ABLE WINDOW

HOPPER WINDOW FOR LAVATOTRY
 Water tanks
3 types of water tanks are provided in LHB coach:

685 liters : 2 stainless steel water tanks of 685 liters capacity each.
These tanks are installed in under frame in twos, are fixed with
frames and are secured by safety belts. These tanks constitute
the fresh water reserves in the passenger coaches. Water level
indicator have been provided in these tanks.
450 liters : One stainless steel water tanks of 450 liters capacity.
These tanks are installed in under frame, fixed with frames and is
secured by safety belts.
3-stainless steel water tanks of 30 liters capacity
installed one in each lavatory in the roof and are continuously fresh-
water-fed by means of pumps. They maintain the good running of
water supply of the barometrical capacitor at each station. These tanks
are installed alone and are fixed with 2 supports which are equipped
with belts.
FIXING DETAILS WITH USE OF RUBBER PACKING
 DECALS
•APPROXIMATELY 50
DIFFERENT TYPES OF
STICKERS HAVE BEEN
USED IN LHB COACH.
DECALS STICKERS
AC 2 TIER
LHB AC Double Decker Coach
Design Development at RCF

91
SEATING CAPACITY 12091
SHELL INSIDE

92
SHELL READY

93
 UNDER FRAME DESIGN
• Beyond front part diamond joint is
connected with Upper deck & Lower deck
underframe

रे ल डिब्बा कारखाना कपरू थला 94

94
SS AC DOUBLE DECKER (EOG)
• ALL SS BODY
• CRASHWORTHY U/ FRAME
• SEATING CAPACITY – 120
• 4 TOILETS
• FRP INTERIOR

रे ल डिब्बा कारखाना कपरू थला 95

95
FIAT BOGIE WITH AIR SPRINGS

96
97
97
 RIDE INDEX
The Quantative Measure of a Ride
Quality is Interpreted as the
Capability of Vehicle Suspension to
Maintain the Motion within range of
Human Comforts. It is Affected by
Many Factors Such as Vibrations,
Acoustic Noise,Smell,Temperature,
Humidity and Seat Designing